When is running warm – too hot?

Managing the heat emanating from electronic devices has always been a challenge and design constraint. Mobile devices present an interesting set of design challenges because unlike a server operating in a strictly climate controlled room, users want to operate their mobile devices across a wider range of environments. Mobile devices place additional design burdens on developers because the size and form factor of the devices restrict the options for managing the heat generated while the device is operating.

The new iPad offers the latest device where technical specifications may or may not be compatible with what users expect from their devices. According to Consumer Reports, the new iPad can reach operating temperatures that are up to 13 degrees higher (when plugged in) than an iPad 2 performing the same tasks under the same operating conditions. Using a thermal imaging camera, the peak temperature reported by Consumer Reports is 116 degrees Fahrenheit on the front and rear of the new iPad while playing Infinity Blade II. The peak heat spot was near one corner of the device (Image at the referenced article).

This type of peak temperature is perceived as warm to very warm to the touch for short periods of time. However, for some people, they may consider a peak temperature of 116 degrees Fahrenheit to be too warm for a device that they plan to hold in their hands or on their lap for extended periods of time.

There are probably many engineering trade-offs that were considered in the final design of the new iPad. The feasible options for heat sinks or distributing heat away from the device were probably constrained by the iPad’s thin form factor, dense internal components, and larger battery requirements. Integrating a higher pixel density display definitely provided a design constraint on how the system and graphic processing was architected to deliver an improvement in display quality and maintain an acceptable battery life.

Are consumer electronics bumping up against edge of what designers can deliver when balancing small form factors, high performance processing and graphics, acceptable device weight, and long enough battery life? Are there design trade-offs that are still available to designers to further push where mobile devices can go while staying within the constraints of acceptable heat, weight, size, cost, and performance? Have you ever dealt with running a warm system that becomes a system that is running too hot? If so, how did you deal with it?